Information injection-pump assembly
BOSCH
9 400 611 403
9400611403
ZEXEL
107691-3281
1076913281
HINO
220401481A
220401481a
Rating:
Service parts 107691-3281 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
23600-3222B
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
14.
NOZZLE
Include in #1:
107691-3281
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 403
9400611403
ZEXEL
107691-3281
1076913281
HINO
220401481A
220401481a
Zexel num
Bosch num
Firm num
Name
9 400 611 403
220401481A HINO
INJECTION-PUMP ASSEMBLY
J08C-TW * K 14CG TICS MD-TI6 TICS
J08C-TW * K 14CG TICS MD-TI6 TICS
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-0920
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
17
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
5.1
5.07
5.13
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
12.2
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
115
112
118
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8+-0.5
Pump speed
r/min
440
440
440
Each cylinder's injection qty
mm3/st.
13.5
12.5
14.5
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
5+-0.03
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.2)
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
115
113
117
Basic
*
Fixing the lever
*
Boost pressure
kPa
53.3
53.3
Boost pressure
mmHg
400
400
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+2.05
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
128
122
134
Fixing the lever
*
Boost pressure
kPa
53.3
53.3
Boost pressure
mmHg
400
400
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R2-0.6)
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
86.5
83.5
89.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
(R2-0.6)
Boost pressure
kPa
18.7
17.4
20
Boost pressure
mmHg
140
130
150
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2(R1-1)
Boost pressure
kPa
40
40
40
Boost pressure
mmHg
300
300
300
Timer adjustment
Pump speed
r/min
0
Advance angle
deg.
0
0
0
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
0
0
0
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
-1.5
-1.8
-1.2
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
0000001601
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2
1.95
2.05
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_02
CU407980-224*
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.1
5.07
5.13
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_03
CU407980-224*
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)When setting the stop lever after governor adjustment, confirm that rack position Ra (point B) can be obtained at the full setting.
(4)Stop lever's normal position setting: RA
(5)Boost compensator stroke: BCL
----------
T1=AF97 Ra=R1+2.05mm RA=(18)mm BCL=(0.6)+-0.1mm
----------
----------
T1=AF97 Ra=R1+2.05mm RA=(18)mm BCL=(0.6)+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=50mm
----------
a=8deg+-5deg b=(36deg)+-3deg
----------
aa=50mm
----------
a=8deg+-5deg b=(36deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa, stopper bolt setting
(2)Speed = bb, rack position = cc
(3)Use the hole above R = dd
----------
aa=(18)mm bb=0r/min cc=1.5+-0.1mm dd=40mm
----------
a=15deg+-5deg b=35deg+-5deg
----------
aa=(18)mm bb=0r/min cc=1.5+-0.1mm dd=40mm
----------
a=15deg+-5deg b=35deg+-5deg
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
----------
aa=5.1+-0.03mm
----------
a=(80deg)
----------
aa=5.1+-0.03mm
----------
a=(80deg)
0000001401
(1)Pointer
(2)Injection timing aligning mark
(3)Fly weight
(4)The actual shape and direction may be different from this illustration.
Operation sequence
1. Turn the prestroke actuator OFF.
2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position.
3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching.
4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark.
5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------
----------
----------
----------
0000001701
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001801
C:Shim
----------
----------
----------
----------
0000001901
A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the counterclockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------
----------
----------
----------
0000002201 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1250r/min Ra=R1(12.2)+2.05mm
----------
----------
N1=1250r/min Ra=R1(12.2)+2.05mm
----------
Information:
1. Locate top center (TC) compressing stroke for No. 1 piston. See LOCATING TOP CENTER COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING. 2. Install the timing fixture plate (A), on the rear face of the accessory drive shaft housing.3. If the plate can be installed with the dowels in the accessory drive shaft housing aligned with the dowel holes in the plate, the accessory drive shaft is correctly timed. Proceed to Step 8. If the plate cannot be installed, continue with Step 4. 4. Remove the cover (1) from the front of the timing gear cover. Remove the accessory drive gear retaining nut and washer. 5. Using tool (B), separate the gear from the accessory drive shaft. Rotate the accessory drive shaft until the timing fixture plate (A) can be installed.6. Install the conical washer on the drive shaft with the O.D. in contact with the gear. Install and tighten the retaining nut to 100 10 lb. ft. (13,8 1,4 mkg). 7. Install the cover (1) on the timing gear cover, and remove the timing fixture plate.8. Position the fuel injection pump housing and governor on the engine, and install the mounting bolts.9. Connect the fuel injection lines and tighten the retaining nut to 30 5 lb. ft. (4,1 0,7 mkg).10. Connect the fuel ratio control sensing line.11. Connect the turbocharger oil supply line and clamp.12. Connect the governor control linkage.
When the governor control linkage is connected the spring tension must hold the governor control lever towards the OFF position.
Separate Governor From Fuel Injection Pump Housing
preparatory steps: a) remove fuel injection pump housing and governor as a unitb) remove fuel ratio control1. Remove idle screw housing plate assembly, and shut down solenoid. 2. Remove two retaining bolts (3) and remove the solenoid fuel shutoff lever (4).3. Remove the idle screw cover (1).4. Remove idle screw housing (2).5. Remove the rack stop collar retaining screw (7). 6. Remove the rack stop collar (5), collar (8), and spring (6).7. Remove the governor-to-fuel injection pump housing mounting bolts (9). 8. Remove the governor housing (10).9. Remove the governor spring (13), seat assembly (11), and washer-type spring. 10. Remove the three mounting bolts (12) and lock that secure the cylinder and weight assemblies (14) to the fuel injection pump housing.11. Pull the cylinder and weight assemblies straight out to clear locating dowels.12. Move the cylinder and weight assemblies sideways to disengage slot in piston from the rack (15).Connect Governor To Fuel Injection Pump Housing
1. Position the cylinder and weight assemblies (1) on the fuel injection pump housing so slot in piston is engaged with the rack (2).2. Push the cylinder and weight assemblies onto the locating dowels. 3. Install the three mounting bolts (5) and lock.4. Install the washer-type spring, seat assembly (4), and governor spring (6) on the cylinder assembly. The washer-type spring should be installed so the outside diameter of spring will contact the guide in governor housing (3).5. Position the governor housing
When the governor control linkage is connected the spring tension must hold the governor control lever towards the OFF position.
Separate Governor From Fuel Injection Pump Housing
preparatory steps: a) remove fuel injection pump housing and governor as a unitb) remove fuel ratio control1. Remove idle screw housing plate assembly, and shut down solenoid. 2. Remove two retaining bolts (3) and remove the solenoid fuel shutoff lever (4).3. Remove the idle screw cover (1).4. Remove idle screw housing (2).5. Remove the rack stop collar retaining screw (7). 6. Remove the rack stop collar (5), collar (8), and spring (6).7. Remove the governor-to-fuel injection pump housing mounting bolts (9). 8. Remove the governor housing (10).9. Remove the governor spring (13), seat assembly (11), and washer-type spring. 10. Remove the three mounting bolts (12) and lock that secure the cylinder and weight assemblies (14) to the fuel injection pump housing.11. Pull the cylinder and weight assemblies straight out to clear locating dowels.12. Move the cylinder and weight assemblies sideways to disengage slot in piston from the rack (15).Connect Governor To Fuel Injection Pump Housing
1. Position the cylinder and weight assemblies (1) on the fuel injection pump housing so slot in piston is engaged with the rack (2).2. Push the cylinder and weight assemblies onto the locating dowels. 3. Install the three mounting bolts (5) and lock.4. Install the washer-type spring, seat assembly (4), and governor spring (6) on the cylinder assembly. The washer-type spring should be installed so the outside diameter of spring will contact the guide in governor housing (3).5. Position the governor housing